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A Level Product Design > Other content > Flashcards

Other content Flashcards

1
Q

What is UCD?

(User-centred design)

A
  • This aims to improve users’ experience of using products.
  • Methods to achieve this involve how users interact with products, gaining anthropometric data, observing other people using products etc.
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2
Q

Some details on the Arts and Crafts movement…

A
  • Simple + natural forms of timber.
  • Traditional joining methods used e.g. ‘mortise and tenon’
  • Designers entail William Morris, Charles Voysey and Richard Norman Shaw.
  • Use of natural patterns
  • ‘Form follows function’
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3
Q

Some details on the Art and Deco movement…

A
  • End of WW1
  • Range of international styles
  • Stylish patterns
  • Bold colours e.g. black and chrome
  • Designers entail Clarice Cliff, Eileen Gray, Rene Lalique etc…

(Art Nouveau is different as this used more natural forms!)

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4
Q

Details of Bauhaus design…

(Modernism)

A
  • Post WW1,
  • Industrial methods and materials
  • Influenced by Art Deco, geometrically pure forms
  • Metalwork, form, furniture design, graphics and more…
  • Form follows function
  • Simple and expensive
  • Designers involved Marcel Bruer, Walter Gropius, Marianne Brandt and more.
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5
Q

Details of Memphis design…

A
  • Against functionality of modernism
  • Bold and bright designs overlooking functonality
  • Human-like or animal-like features.
  • Simple and may be designed to shock
  • Designers entail Martine Bedine, Michele De Lucchi and more…

(From Milan)

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6
Q

Dieter Rams’ ten principles of good design…

A

A good design is…
- Innovative
- Makes a product useful
- Aesthetic
- Makes a product understandable
- Unobtrusive (not overdone)
- Honest
- Has longevity
- Thorough down to the last detail
- Eco-friendly + little design as posssible

(He follows ‘form follows function’)

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7
Q

What is the COID?

(Council of Industrial Design)

A

Desinged to improve…
- Design standards via training
- Country’s competitiveness in a post-utility environment

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8
Q

What is the IoT?

A
  • The networking of multiple microelectronic devices using wifi and the internet…
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9
Q

Stages of the product lifecycle…

A
  • Introduction
  • Growth
  • Maturity (most profits made here).
  • Decline/removal
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10
Q

What is Six Sigma…

(With steps)

A
  • Define the issue of requiring improvement
  • Measure the issue’s extent
  • Analyse where the measured issues occur
  • Improve via rectification processes
  • Controlled modified procedures via effective QA.

(Process improvement to reduce defects to lower than 3.4 in a million)

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11
Q

Polymer enhancement…

(Material enhancement)

A
  • Lubricants reduce viscosity, making moulding easier due to low temperature, saving energy.
  • Thermal antioxidants prevent the polymer from discolouration or oxidation.
  • Pigments give colour.
  • Flame retardants prevent combustion/spread of fire.
  • Plasticisers make plastics less hard and brittle at normal temperature. + Biodegradable plasticisers make polymers more flexible + reduces degradation time.
  • Fillers provide product bulk.
  • Bio-batch additives can reduce degradation time from hundreds of yrs to a few months.
  • Antioxidants help reduce polymer deterioration from oxygen exposure.
  • UV light stabilisers prevent polymer chains breaking down from sunlight -> could lead to colour loss/brittleness.
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12
Q

Wood enhancement…

(Material enhancement)

A
  • Resins and laminations enhance engineered wood e.g. manufactured boards.
  • Fire retardant resins prevent spread of fire.
  • Laminations - Lamniated veneers can enhance aesthetics.
  • Preservatives protect wood from insect/fungal attack.
  • Pigments provide aesthetics
  • Fire-retardant preservatives can make wood more harder + more resistant.
  • SCL + LVL can prevent things like warping, splitting and shrinking.
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13
Q

Some examples of marketing/brand identity…

A
  • Labelling
  • Packaging
  • Corporate identity (used to present the image of a company to the public).
  • Global marketing (promoting a product or service worldwide)
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14
Q

2D and 3D drawing types…

A

2D drawings:
- (Orthographic projection) is used to draw the front, plan and elevation of an object/building, so they can be understood by engineers.
- (Sectional drawings) used to show inernal, hidden details of an object
3D drawings:
- (Isometric) Typically used to sketch design ideas + uses parallel lines and 3 degree lines are used.
- (One-point perspective) Typically used to sketch buildings/rooms + Can create design ideas in 3D
- (Two-point perspective) Similar to one-ppint perspective and may have 2 perspectives.

(Check google drive)

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15
Q

CPA details…

(Design for manufacture and project management)

A
  • CPA analyses individual stages in a project, and an efficient time each element of a process to be completed.
  • This can reduce process time.
  • CPA requires deadlines, list of all activities, estimate of the time each stage will take etc.
  • Format of critical path -> Letter (e.g. A) | duration (seconds)

(Critical path analysis)

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16
Q

Some details on lean manufacture…

(Design for manufacture and project management)

A

-A systematic approach to production which aims to eliminate all waste from product production.
- (Transport) reduce distance to reduce chances of damage, loss, delays etc
- (Inventory) Reduce amount of raw materials and finished goods, (any stock held on site is at risk of damage and loss in value), which could delay final sales.
- The acronym is then movement, waiting, over production, over processing, defects.

(Reduce waste)

(TIMWOOD)

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17
Q

Go/no gauge details…

(Design for manufacture and project management)

A
  • Checks whether a single measurement fits within a tolerance range -> gives a pass/fail reading.
  • Quicker than a vernier calliper or micrometer as operator does NOT need to check for accurate reading.
  • Little training required to operate go/no gauge -> no adjustment/recalibratiion required.
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18
Q

Co-ordinate measuring machinery…

(Design for manufacture and project management)

A
  • CMMs e.g. probe scanner allow a manufacturer to check predefined measurements on finished components.
  • Very high accuracy, and is compared to a 3D CAD model and is logged onto a computer.
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19
Q

Details on Charles and Ray Eames…

A
  • Influential U.S designers who heavily contributed to furniture design and architecture.
  • They were well knwon for using plywood and using complex techniques for things like bending techniques.
  • The Lounge Chair and the Ottoman are examples of some products that were made.
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20
Q

Types of production…

A

One-off
Batch
Mass

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21
Q

Pros and cons of CAD…

A

Pros:
- Speeds up design and development process
- Makes collaborative work easier
- Can be operated on by CAM equipment or can be sent to 3D printers.
Cons:
- High start-up costs
- Regular updates may be required
- May require skill for usage.
-

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22
Q

CAM processes…

A
  • Laser cutting
  • Routing
  • Milling
  • Turning
  • Plotter cutting and virtual modelling
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23
Q

Rapid prototyping processes…

A
  • CFD (computational fluid dynamics)
  • FEA (finite element analysis)
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24
Q

Paper and board processes…

A

Die cutting:
- Used to cut out paper or card ‘nets’ when forms a 3D shape when assembled. | Die cutters use a substrate into which steel cutting dies + creasing rules are inserted -> Creasing rules score net parts to be folded
- Bending -> In industry, larger machines may carry out die cutting, creasing and folding in one process.
- Laser cutting -> Useful for small-scale production or bespoke production

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25
Q

Kanban…

A

This controls the movement of materials and components from suppliers through a factory

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26
Q

EPOS…

A
  • This used barcodes or computer entry to transmit customer orders to suppliers and manufacturers.
  • Can be used for other things e.g. stock
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27
Q

MPS…

A
  • This determines the no. of products which will be made in a specific timeframe
28
Q

RFID…

A
  • RFID uses small electronic devices that can be scanned and used to track moving items through a factory into dispatch.
29
Q

AGV…

A

Robots, similar to forklift trucks, used to carry materials and finished goods around a factory..

30
Q

Circular economy…

A

A system where materials are never wasted, but may be regenerated

31
Q

What’s the main piece of legislation for British health and safety law?

A

HSWA (1974)

32
Q

Brazing…

(Metal redistribution processes)

A
  • Can be used to join dissimilar metals e.g. low carbon steel to aluminium. + Can be used to join thin gauge metal e.g. low carbon steel or bar
  • Material cleaned, -> two pieces joined, -> flux applies to stop oxidation -> Joint heated -> Brazing rod applied to joint area for joining
33
Q

Soldering…

(Metal redistribution process)

A
  • Used for lightweight applications and thin gauge metals + Often used for precious metals e.g. gold and silver
  • Metal cleaned -> Joint area clamped -> etal heated to solder melting point -> Solder added to metal and will flow along joint via capilliary action -> Metal cleaned to remove flux residue
34
Q

Riveting…

(Metal redistribution process)

A
  • Permanent joining method used to join sheet metal or plate. + Pop riveting is used for joining thin sheet metal.
  • Pop riveting is ideal when underneath the joint is inaccessible.
35
Q

Steps on lamination (lay-up)…

(Polymer forming process)

A
  1. Mould is prepared
  2. Release agent e.g. wax or PVA coats mould, or parcel tape is used.
  3. Gel coat applied to mould top, to perhaps prevent product degradation.
  4. Fibreglass matting cut accordingly and laid over former/mould
  5. Another gel coat is applied and the material sets
36
Q

Pros and cons of lamination (lay-up)…

(3D products from just composite-based materials)

A
  • Relatively cheap and can have large applications
  • However, mixed fibres may be restricted and surroundings may need to be at room temperature.
37
Q

Steps on injection moulding…

(Used for thermoplastics and complex items)

A
  1. Thermoplastic granules are fed ino hopper.
  2. Motor rotates the Archimedean screw, pulling the granules past electric heaters
  3. Heaters melt the polymer
  4. When enough polymer has melted and formed at screw’s end -> hydraulic ram forces screw thread forward -> injecting the polymer into the mould
  5. Mould is water cooled + Allowing molten polymer to harden
  6. Ejector pins push mould out as mould opens
  7. Excess polymer cut off + Moulding cools or solidifes -> Former may maintain moulding’s dimensional accuracy.

(Check google drive)

38
Q

Pros and cons of injection moulding…

A
  • Can be used for large-scale mass production.
  • However, initial cost of setting up this is very high.
39
Q

Pros and cons of thermoforming…

(Used to mould additional detail into polymer’s surface).

A
  • Can be used in industry easily + Fine details can be achieved
  • However, can be a slow process.
  • Can be used in food packaging
40
Q

Steps on thermoforming…

A
  1. A mould is placed into the plastic sheet and is heated, and is removed.
  2. For extra detail, the two moulds trap the softened polymer in between.
41
Q

Pros and cons of vacuum forming…

(Used for lightweight 3D products from thermoplastics)

(Can be used for food packaging)

A
  • Relatively easy to make + Can be used for continuous production
  • Not effective for one-off production
42
Q

Steps on vacuum forming…

A
  1. Mould placed on machine bed + then lowered
  2. Heater pulls over polymer sheet as its clamped into mould
  3. Platen raised into polymer + heat removed as polymer sheet softened
  4. Vacuum pump sucks the polymer onto mould
  5. Once polymer is cooled and solidified + Platen lowered and vacuum pump turns off.
  6. Mould is removed + Excess polymer removed
43
Q

Pros and cons of blow moulding…

(Used to make hollow products, common polymers are PET, LDPE etc)

(Can be used to make bottles and plastic carrier bags)

A
  • Can be used in continous production
  • However, high setup costs

(Injection blow moulding can be used in threads)

44
Q

Steps on blow moulding…

A
  1. Polymer is fed into the hopper
  2. Archimedean screw melts pulled polymer in the heated section
  3. Melted polymer extruded as a ‘parison’
  4. Around the parison, mould sides close + Injected air forces polymer to the sides.
  5. Polymer cools, mould opens + finished bottle ejected
45
Q

Pros and cons of compression moulding…

(Used to mould thermosetting polymers e.g. MF,UF etc)

(Products entail electrical sockets, electrical light fittings)

A
  • Good for producing large parts
  • However can produce a lot of waste
46
Q

Steps on compression moulding…

A
  1. Thermoset polymer is inserted into pre-heated moulds.
  2. Mould closes + Hydraulic pressure applied to allow polymer to take the mould’s shape.
  3. Cross-linking occurs + Thermoset ‘cures’ whilst moulds are closed.
  4. Once thermoset cures, machine opens and product is removed
  5. Excess polymer removed
47
Q

Pros and cons of rotational moulding…

(Used to make heavy duty hollow objects e.g. kayaks, traffic cones etc)

(Used for thermoplastics e.g. HDPE and PP)

A
  • Moulds can be changed quickly during operations and can be used for barch or mass production
  • However, high set-up costs
48
Q

Steps on rotational moulding…

A
  1. Polymer granules enter mould to clamped and sealed
  2. Mould is heated to 260 -370 celcius in an oven
  3. Polymer is coated via a fan or water once it has correct thickness.
  4. Polymer slightly shrinks once its solidififed, allowing it to be removed.
49
Q

Pros and cons of extrusion…

(Used for products with ‘I’ or ‘T’ sections)

(Mostly thermoplastics are used, e.g. polymer electrical wires)

A
  • Can be used in continuous production…
  • However, only by specialist manufacture
50
Q

Steps on extrusion…

A
  1. Polymer granules fed into hopper
  2. Archimedran screw moves granules past heaters
  3. Heaters soften the polymer
  4. Archimedean screw pushes hydraulic ram which pushes the polymer through a steel die.
  5. Extrusion is cooled by air or water, supported by rollers.
  6. Extrusion cut to desired length.
51
Q

Pros and cons of pewter casting…

(Suitable materials are aluminium, pewter or steel)

(Used for small scale products, or decorative compnents for larger products e.g. jewellery or key fobs).

A
  • Suitable for one-off production and high scale production.
  • If high scale production required, pewter can be changed to a material like aluminium
52
Q

Steps on pewter casting…

A
  1. Mould (from manufactured board) is made + If mould is MDF or plywood, its fret saw cut or laser cut + For pewter to enter mould, mould will jave a runer or sprue.
  2. Pewter cast mould is clamped and sandwiched together with 2x MDF pieces + Mould top will be level with top of side pieces.
  3. Pewter is melted in a ladle, and the pweter goes through the sprue into the mould.
  4. Casting removed from mould once its cooled.
  5. Sprue/riser is removed with a junior hacksaw.
  6. Abrasive wet and dry paper cleans up filed casting + casting polished.
53
Q
  • Pros and cons of die casting…

(Used for low-melting point metals e.g. aluminium or zinc-based alloys).

(Gravity, hot chamber and cold chamber).

A
  • Can involve usage or reusable steel moulds + Gives a high-quality surface finish
  • However, complexity of dies and productions costs mean die casting is only used in large batch or mass production.

(Products entail door handles, engine components and alloy wheels).

54
Q

Gravity die casting steps..

A
  1. Metal is melted and poured into mould (relies on gravity to go through mould)
  2. Runner pours molten metal into mould, and it goes into riser once mould is full.
  3. Mould opens and casting is removed once metal is cooled.
55
Q

Steps on hot chamber pressure casting…

A
  1. Molten metal stored in chamber
  2. Plunger forces a ‘shot’ of molten metal into die via gooseneck, from high pressure
  3. Mould is filled + Fine detail used

(A fast process and aluminium is NOT used).

56
Q

Steps on cold chamber pressure die casting…

A
  1. Molten metal is ladled into shot chamber
  2. Hydraulic ram forces motlen metal into cavity
  3. Ejector pins eject hardened metal.
57
Q

Steps on investment casting…

(Useful for awkward and intricate items e.g. medical applications and cast jewellery).

A
  1. Wax replica of the product is made, and a replica runner is made.
  2. Refractory clay coats wax replica
  3. Molten is poured into the clay mould
  4. Once mould is full, metal cools.
  5. Casting removed with broken clay mould
  6. Runner and other connected channels machined off.

(Used for high-quality products due to wax patterns being cast from master mould)

58
Q

Steps on sand casting…

(Products involve park benches and post boxes)

(Suitable materials are high-melting point metals)

A
  1. Replica made and placed into steel box -> then filled with sand and is levelled
  2. Steel box turned over and second box clamped over this -> Top half of pattern joins bottom half, following the runner and riser later
  3. Sand is packed into second box
  4. Boxes split and pattern ejects.
  5. Metal spikes make ventilation
  6. Molten metal poured to form product.

(Process is laborious and slow)

59
Q

Details on rolling…

(Metal redistribution process)

A
  • Hot rolling = Material with mechanical properties that are nNOT uniform
  • However, outside carbon deposits need to be removed via acid picking.
  • Cold rolling = Tighter tolerance + no carbon deposits -> Products involve home appliances and electrical appliances.
60
Q

Steps on drop forging:

(Quick process and is used in mass production)

(Suitable for most metals)

A
  1. Cast tool steel due secured to anvil top.
  2. Ram equips a mould-resembling die.
  3. Metal to be forged heated, preventing work hardening and brittleness.
  4. Heated ‘billet’ placed into anvil die with tongs, and billet spreads around die shape.
  5. Ram lifted and product removed.

(Small-scale products e.g. pliers and spanners are made from this)

(Dies can be changed fast to make other items with same hydraulic ram).

61
Q

Steps on press forming…

(Can be used in high scale production however making die is costly and requires high skill)

A
  1. Sheet metal clamped over product die
  2. Hydraulic press pushes due into sheet metal
  3. Hydraulic die is lowered and the pressed sheet component is removed
  4. Sheet may be placed into further press forming machines for additional pressing, where the shape is complex.

(Used to make sheet metal into 3D forms).

Products involve car body panels, boxes and containers.

62
Q

Steps on spinning…

(Metal process for radial symmetry)

A
  1. Former put on the chuck with sheet metal beld between chuck and tail stock
  2. Roller tool moved into the blank and is rotated with former, which starts to stretch metal over the chuck.
  3. Roller tool moves along former as pressure is maintained against the rotating blank
  4. Roller tool moved to former’s end whilst keeping blank contact, finishing the product shape.
  5. Finished product removed from former and excess material trimmed off.

(Typically used in mass production and can be set up via CNC machines and can be used in batch production, however, simple formers do not justify costs)

63
Q

Details on cupping and deep drawing…

High set-up costs make is suitable for mass or continuous production of same items.

A
  1. Pressing blank clamped over deep drawing die with a pressure pad or clamping ring known as a retainer
  2. Hydraulic press moves the deep drawing punch to be in contact with blank + Press pushes blank into die cavity to form a cup shape.
  3. Cup is then pressed further down through deep drawn die to make desired tube shape.

(Used to form tube-like shapes e.g. fire extinguishers and hihg pressure aerosol cans).

64
Q

Some types of nutrients associated with the circular economy…

A
  • Biological
  • Technical
65
Q

Laser beam welding

A

Pros:
- Can weld dissimilar metals and a range of metals
- No filler rods or finishing processes needed
Cons:
- High capital cost
- Need comfort health and safety and a clean environment

66
Q

Electrohydraulic forming…

A
  • Single stage of forming of complex sheet metal parts using a single sided former.
  • Good thing is how just one sided former required + Very fast, even distribution of material and renge of materials can be used.

A Level Product Design (6 decks)

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